kaiser_will

VersaMax is a GE PLC platform.  Have you tried to post this in the GE forum here? You have a GE VersaMax PLC, a GE Proficy process SCADA PC, and they all communicate on a Modbus RTU network.  Where do you want to send the coil states on the Modbus RTU network?  Does this location have access from the Proficy SCADA PC?  If so, and if you desire no control other than to share data, then yes I see it possible for the Proficy SCADA PC to perform the function.

Refer to the attached Work Instruction for references on RSLinx. Your screenshot of PLC Channel 2 Configuration notes "DF1".  DF1 is a serial-type protocol but is NOT serial protocol; DF1 requires a different cable pinout. - Determine which PLC port you will utilize and configure in RSLogix500 - Cable the configured PLC port into the HMI - Configure RSLinx communication  Work Instruction - Allen-Bradley SLC Communications Setup.doc

Post a screenshot of your RSLinx configuration, please. Allen-Bradley/Rockwell utilizes RSLinx as the communication layer control for most of their PLCs.  Logix500/Logix5000/Studio5000 are the PLC programming packages, but all require RSLinx for communication.   MicroLogix 1400 has ports...RS-232 (8-pin mini-DIN), RS-232 (DB-9), Ethernet/IP, DH-485 (with use of 1763-NC01)  http://literature.rockwellautomation.com/idc/groups/literature/documents/sg/1761-sg001_-en-p.pdf Beijer iX-T5F-2 HMI has ports...Ethernet, Serial (RS-232, RS-422/485)  http://beijerinc.com/pdf/iX-T5F-2-datasheet.pdf Select your communication protcol based on your hardware => RS-232 is probably the best choice Configure the PLC serial port and the HMI serial port so that they can communicate.  How have you configured the Beijer HMI serial port?  HMI should have connected at COM1 or COM3 for RS-232. On the MicroLogix 1400, Channel 0 is isolated and Channel 2 is non-isolated.  Channel 0 is preferred for serial communication devices, as it is isolated and has driver control integrated.  http://literature.rockwellautomation.com/idc/groups/literature/documents/um/1766-um001_-en-p.pdf

The PanelView Standard Series, to which the PV550 was a member, went Silver Series (i.e., marked to become obsolete) starting in 2011/2012.  Rockwell/A-B typically phases out a product line over a number of years (Phase 1 - Make the plans known, Phase 2 - Internal components stopped production but can still buy new assemblies, Phase 3 - No new assemblies but will repair and support, Phase 4 - No repair but will support, Phase 5 - You had many years to be on your own). http://www.rockwellautomation.com/global/solutions-services/capabilities/migration-solutions/product-search/results.page A-B suggests migrating PV550-Keypad to PV Plus 600-Keypad & migrating PV550-Touch to PV Plus 600-Touch. Under similar circumstances, we exhausted buying up all surplus new-old-stock or used PV Standard models (Plan A).  Then get cracking on engineering up a migration path, either to the PV Plus 600 or a comparable manufacturer (Plan B).  Overall, there are a many HMI models that have the communication ports you desire. Do you have a concise audit of the models in-use and your spare parts in-house?  Page 11 has a breakdown of the PV550 alphabet soup part numbers and their communication options.  http://literature.rockwellautomation.com/idc/groups/literature/documents/td/2711-td007_-en-p.pdf

I believe the ML-series high-speed inputs utilize mapping the high-speed inputs into the HSC block which acts similar to the SLC-500 "IIM" (Immediate Input with Mask).  Since you are not using the HSC function, you could utilize the IIM function and get the code to respond to encoder pulse train input change.  Refer to page 229.  http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/1762-rm001_-en-p.pdf The early I/O-based processors (SLC-500, PLC-5, early MicroLogix) read inputs, execute logic, update output table.  The IIM function interrupts the typical scan cycle when the designated input changes per the mask (one can mask out low or high bits to not respond to "noise"), executes that logic, then returns to where it was in the read/execute/update scan. With IIM functions, create a new ladder for the IIM code, set the ladder reference in the IIM block of the Settings. Essentially, the high-speed inputs if not utilized through the HSC block does not gain the advantages of high-speed control.  Using a high-speed function, such as the IIM, gets you the fast action you are looking for.

Rockwell/Allen-Bradley has a development software package, Motion Analyzer, that is well suited for this application.  With the software, one can model the mechanics of an application and determine if the servo motor and controller are sized properly, if the VFD can move a load within a time period.  http://ab.rockwellautomation.com/Motion-Control/Motion-Analyzer-Software With A-B systems design, the critical components are servo motor/controller sizing (and if a gearbox is needed) & VFD motor/controller sizing (and if a gearbox is needed), as well as if the PLC controller can handle the motion tasks. One can download for free, trial run period is 30 days without license.  http://www.motion-analyzer.com/download.action Motion Analyzer is a software package developed by Electrical Engineers as a tool really for Mechanical Engineers.  So it ends up being overly complicated and cumbersome until you figure it out.  I have a simple Work Instruction, developed for our Mechanical Engineers to make the software application productive for them.   Work Instruction - Allen-Bradley Motion Analyzer Software.doc

The specification is still wide open, then.  Where does "our geometry is not supported come from"?   If the goal is to design a 2D plotting device, I would say high precision is required => servos.  Before you pick the servo controller, one must pick the servo motor that will need the motion requirements (mass to move, maximum speed required, travel distance).  The servo motor family will dictate the servo controller.

The scope...PET bottle is seen by a photoeye, PLC sees photoeye one-shot event, capture encoder position counts, PLC logic BSL to trigger an air blowoff nozzle when target encoder counts is measured. Ideally, for an encoder and to insure scalable accuracy as line speed is varied, the encoder should be wired into high-speed inputs.  Are you using the high-speed inputs?  ML1200, for HSC function can utilize inputs 0-3.  These high-speed inputs map into dedicated a HSC high-speed counter register. If the encoder is wired into high-speed inputs, are you using the built-in HSC register, or are you using the input registers for encoder position? Are you using a single-ended encoder or a quadrature encoder?  A quadrature encoder should give you better scalable resolution compared to a single-ended encoder. Judging by 60 PPR, I suspect you are using a single-ended encoder with low resolution.  Higher resolution and quadrature should give you better accuracy.

When you say you are trying to open a FTView Studio project last opened with Ver 5, how did this Ver 5 project wind up on your development PC?  If you copied the project, the APA application file, FTView Studio does not see it in its HMI Projects folder. FTView Studio requests to store ALL FTView "restored" projects to a specific location (C:\Users\Public....\HMI Projects). Is the restored, Ver. 5 application physically located in the target directory (C:\Users\Public....\HMI Projects)? Have you tried, instead of selecting "Search Sub-Folders", to select the Browse button to the right and drilling to the location of the restored, Ver 5 application?

What is the full part number of the obsolete Cutler-Hammer PanelMate 1700?   There are many companies that market USED control system components.  Used controls are often rated to their condition...NIB (New In-Box, never opened, factory seal, typically 50% of list), NOB (New Open-Box, opened box but new, typically 25-50% of list), Used-No Box (~ 25% of list), and Used (15-25% of list). Some markets or applications may block the use of "surplus" controls, but other markets have no issue getting their down process back in action with a used HMI.

A SLC PLC is an early-generation controller that does not hold the PLC program rung descriptions and comments; you will need to have the most-recent program with rung descriptions and comments.   The SLC-5/03 processor has a DH-485 port (similar to an RJ-45 Ethernet port, Channel 1, but is physically wider) and a DH-485/DF1/ASCII port (DB-9).  To program a SLC-5/03 you will need a communication cable.  A 1747-CP3 RS-232 serial cable will suffice, or a 1747-PIC box. http://literature.rockwellautomation.com/idc/groups/literature/documents/in/1747-in518_-en-p.pdf https://www.plccable.com/allen-bradley-programming-cable-1747-pic-slc-5-00-5-03/ The last piece of the pie is communication software.  Yes, RSLogix500 will give you ability to program the PLC, RSLinx is required for the communication connection.  All A-B Logix PLCs require RSLinx for the communication; RSLinx is typically bundled with RSLogix500, but be forewarned you will need both installed.

Your description of the system is top-view.  How about the hardware.  Are your axes VFD-driven or servo?  Which servo controllers are you using?  Which PLC platform are you using?

Where is the error being generated, in the CompactLogix 5370?  When did this problem occur (new build or existing machine)?

In cases in which a control system is setup, addressed and functional, and in which it will be connected to an IP network with a different addressing scheme, a managed Ethernet switch that supports IP Address Aliasing (i.e., NAT or Network Address Translation) is suggested.  A-B Stratix 5700 is such a model.  http://literature.rockwellautomation.com/idc/groups/literature/documents/wp/enet-wp032_-en-e.pdf Basically, the connection point to the control network (PLC 10.10.1.xxx) you convert in the Ethernet switch to what your LAN requries (192.168.1.xxx).  The switch has a simple lookup table and converts 10.10.1.xxx to 192.168.1.xxx.

A-B PLC scan time & Ethernet/IP network availability go hand-in-hand.  The problem, most likely, is not the PLC scan time but the network availability.  Is the control LAN separated from the company LAN?  How many devices reside on the control network?  How "tight" is the control network (a loose control network design can afford significant latency delays)? WireShark is a free IP Network Analyzer tool.  I would suggest plugging into the control network, turn off all ports not directly connected (such as Wireless), let WireShark run, research what results you are given.  Broadcast traffic, typical A-B processors are known to generate, are often the main culprit.

What model of PanelView 1000 are you working with?  What version of FTView ME are you using?  Why do you want to change other user's passwords? Allen-Bradley/Rockwell does not offer ability for PView app developers to know what user passwords were used, that I am aware of.   You could open the APA project file in FTView ME, reset all user passwords, create the MER runtime file, and download.  It is not knowing what the passwords are, but resetting all.

Try reducing the number of registers written to a smaller number

When you say "shows errors on the display graphics", could you be more precise?  A screenshot tells the story the best for the forum.

Some manufacturer platforms one has to index up or down one step to get the Modbus TCP registers to line up.  Try to reduce the number of WRITE registers written until you can verify handshaking.  

Have you built a spreadsheet to total all I/O module current usage to calculate a rack current total, then add up all rack totals?  For typical 1732 Armor Block networks, one should have a backbone with power drops. Chapter 4 walks you through calculating current load for the number/type of modules per rack, number of racks per network and specifying the cables as such.  This guide will also clarify the communication and power cables needed to network the racks together.  The best way to daisy-chain the rack is to follow the specifications.  If you have too much load on a network drop, then you will be forced to split the system into multiple networks.  http://literature.rockwellautomation.com/idc/groups/literature/documents/sg/1732-sg001_-en-e.pdf

If you want to reset, zero, the PF525 encoder position, this process will be the same as a Manual Homing procedure.  Appendix E - Pg. 210.  You will need digital term block inputs to be "37" (position redefine), then issue a RUN command to the drive.  An alternative is to toggle bit A560.   Take note of the IMPORTANT...Position Redefine input or bit must be returned to inactive before starting position routine.  (1) Toggle Position Redefine command, (2) Latch PF525 RUN command. Before implementing the Manual Home procedure, make sure any previous VFD inputs/commands are in their proper state.

Allen-Bradley/Rockwell offers many PLC trainer suitcases.  These often go up on Ebay as used machines.  Basically a PLC/power supply with a number of I/O built into a demo suitcase.  However, not in your $100 budget.  http://www.ebay.com/itm/ALLEN-BRADLEY-RSLogix-500-MICROLOGIX-1000-1761-L16BWA-COMPLETE-PLC-TRAINER-/182681910399?hash=item2a88b0bc7f:g:1xEAAOSwzgBYzU5D You can pickup a used Allen-Bradley PLC from a number of surplus electronics distributors.  Typical surplus electronics cost is 25% of list if used/opened box and 50% of list if new/unopened box.

SLC rack and bad power supply may be indicative of a failing chassis.  Many of us have run into this gremlin before.  Difficult to troubleshoot until you abandon all options, swap out the rack, and your nuisance problems go away.  http://www.plctalk.net/qanda/archive/index.php/t-48534.html

For Allen-Bradley PLC training, your options are:  A-B technical classes, A-B "on-the-move" labs (typically free and short), 3rd party classes/labs, online training classes, read the extensive literature. Refer to Chapter 20 of the MicroLogix 1400 User Manual for background on the PID function.  http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/1766-rm001_-en-p.pdf Allen-Bradley has a manual for the enhanced PIDE function used in Compact/ControlLogix processors.  Not the same function block as the PID (SLC-500 based), but the background fundamentals are the same. The subject of PID loops is not a quick black and white answer, but is essential for many programming applications and has been around a long time.  Think of a PID control loop like the sloppy steering of your dad's old pickup truck.  Sloppy steering (wide range of motion), your faster response to compensate for the sloppiness (time response), smaller adjustment when you do compensate (amount of gain).  

Does your SLC PLC have a memory module, that could be loading the OLD program on startup?